PV module power electronics mounting system with compression spring

ABSTRACT

An apparatus and system for mechanically coupling a power conditioning unit (PCU) to a photovoltaic (PV) module. In one embodiment, the apparatus comprises a base member, adapted for mounting a power conditioning unit (PCU) on a PV module backsheet, comprising a plurality of PCU retention members for retaining the PCU; and at least one compression spring, coupled to the base member, for maintaining the PCU in a position, with respect to the PV module backsheet, that can be dynamically changed between a first position and a second position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 15/267,894, which was filed on Sep. 16, 2016 andwhich claims benefit of U.S. provisional patent application Ser. No.62/219,884, entitled “PV Module Power Electronics Mounting System withCompression Spring” and filed Sep. 17, 2015, which is hereinincorporated in its entirety by reference.

BACKGROUND OF THE INVENTION Field of the Invention

Solar panels, or photovoltaic (PV) modules, convert energy from sunlightreceived into direct current (DC). In some solar power systems, the PVmodules may be coupled to power conditioning units (PCUs), such as DC-DCconverters or DC-AC inverters, in a distributed architecture; i.e., onePCU per PV module. In such systems, each PCU may be mounted to the face(i.e., backsheet surface or superstrate) of the corresponding PV module.

One technique known in the art for mounting a PCU to a PV module face isa sliding rail backsheet mount system. In such a system, mounting railsare adhered to the PV module face and the PCU can be slid along therails into position. However, the sliding rail system requires almosttwice the footprint of the PCU in order to insert/remove the PCU (due tothe PCU having to slide up/down the rails) and maintains the inverter ina fixed position which respect to the PV module which may not be idealfor shipping combined PCU/PV module assemblies.

Therefore, there is a need in the art for an apparatus for efficientlymounting a power conditioner to a PV module frame

SUMMARY OF THE INVENTION

Embodiments of the present invention generally relate to an apparatusfor mechanically coupling a power conditioning unit (PCU) to aphotovoltaic (PV) module substantially as shown and/or described inconnection with at least one of the figures, as set forth morecompletely in the claims.

Various advantages, aspects and novel features of the presentdisclosure, as well as details of an illustrated embodiment thereof,will be more fully understood from the following description anddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 is a block diagram depicting a physical layout of a photovoltaic(PV) system in accordance with one or more embodiments of the presentinvention;

FIG. 2 is a top angled perspective view of a PCU mounting assemblycoupled to a PCU in accordance with one or more embodiments of thepresent invention;

FIG. 3 is a top angled perspective view of a PCU mounting assembly inaccordance with one or more embodiments of the present invention;

FIG. 4 is a top angled perspective view of a PCU mounting assembly inaccordance with another embodiment of the present invention; and

FIG. 5 is an angled bottom view of a PCU mounting assembly.

DETAILED DESCRIPTION

Embodiments of the present invention generally relate to a mountingassembly for mounting a power conditioning unit (PCU) to a photovoltaic(PV) module. The mounting assembly comprises a base member havingmultiple retention members for retaining the PCU. The mounting assemblyfurther comprises at least one compression spring that maintains the PCUin one or two positions with respect to the PV module and allows the PCUposition to be dynamically changed. In a first position, the PCU ispressed flat against the backsheet of the PV module, while in the secondposition an airgap is present between the PCU and the PV modulebacksheet for thermal management.

FIG. 1 is a block diagram depicting a physical layout of a photovoltaic(PV) system 100 in accordance with one or more embodiments of thepresent invention.

The PV system 100 comprises a plurality of power conditioning units(PCUs) 102 ₁, 102 ₂ . . . 102 _(n) (collectively PCUs 102, or powerelectronics 102), a plurality of PV modules 104 ₁, 104 ₂ . . . 104 _(n)(collectively PV modules 104), and a plurality of PCU mountingassemblies 150 ₁, 150 ₂ . . . 150 _(n) (collectively PCU mountingassemblies or mounting assemblies 150).

Each PV module 104 ₁, 104 ₂ . . . 104 _(n) comprises a structural frame160 ₁, 160 ₂. . . 160 _(n), respectively, collectively referred to asframes 160. Each of the frames 160 surrounds the perimeter of thecorresponding PV module 104 and may be constructed of any rigidmaterial, such as aluminum, rigid plastic, and the like, or anycombination of such rigid materials. The frames 160 of the PV modules104 are generally coupled flush with the frames 160 of neighboring PVmodules 104 in a horizontal direction.

Each PCU 102 ₁, 102 ₂ . . . 102 _(n) is mechanically coupled to acorresponding PV module 104 ₁, 104 ₂ . . . 104 _(n) via a correspondingmounting assembly 150 ₁, 150 ₂ . . . 150 _(n), respectively, in aone-to-one correspondence. Each mounting assembly 150 ₁, 150 ₂ . . . 150_(n) is adhered to the surface of a respective PV module backsheet 180₁, 180 ₂ . . . 180 _(n) (i.e., the rear PV module face that is notexposed to sunlight) for retaining the corresponding PCU 102 ₁, 102 ₂ .. . 102 _(n) proximate the PV module 104 ₁, 104 ₂ . . . 104 _(n). Eachcombined PV module 104/PCU 102/mounting assembly 150 may be referred toas a power module assembly.

In accordance with one or more embodiments of the present invention,each of the mounting assemblies 150 ₁, 150 ₂ . . . 150 _(n) comprisesone or more compression springs 130 ₁, 130 ₂ . . . 130 _(n)(collectively compression springs 130), respectively, that enables thecorresponding PCU 102 to be pressed flat to respective the PV modulebacksheet 180 ₁, 180 ₂ . . . 180 _(n) (collectively referred to as PVmodule backsheet 180), for example during shipping, and, once installed,to be retained proximate the corresponding PV module 104 with a definedgap between the PCU 102 and the PV module 104 that allows airflowbetween the components for thermal management of the PCU 102 and the PVmodule 102. In some embodiments, the gap may be on the order of 5-25 mmand may depend on topology features of the PCU enclosure.

In addition to being mechanically mounted to the PV modules 104, thePCUs 102 ₁, 102 ₂ . . . 102 _(n) are electrically coupled to the PVmodules 104 ₁, 104 ₂ . . . 104 _(n) to receive the generated DC powerfrom the corresponding PV module 104. Examples of such coupling may befound commonly assigned U.S. patent application Ser. No. 14/793,164,entitled “Photovoltaic Module with Integrated Power Electronics”, filedJul. 7, 2015, which is herein incorporated in its entirety by reference.

In some embodiments, the PCUs 102 are DC-AC inverters for inverting DCpower generated by the PV modules 104 to AC power. In such embodiments,the PCUs 102 are coupled to a load center 108 via an AC bus 106 fordistributing the AC output produced by the PCUs 102. The load center 108may house connections between an AC commercial power grid distributionsystem and the AC bus 106 for coupling the generated AC power to thegrid. Additionally or alternatively, the generated AC power may becoupled to commercial and/or residential systems via the load center108, as well as stored for later use (for example, the generated energymay be stored utilizing batteries, heated water, hydro pumping,H₂O-to-hydrogen conversion, or the like).

In other embodiments, the PCUs 102 may be other types of powerconditioning units; for example, the PCUs 102 may be DC-DC convertersand the bus 106 may carry DC energy to a DC power distribution systemand/or to a single centralized DC-AC inverter. The generated DC powermay additionally or alternatively be supplied directly to commercialand/or residential systems via the load center 108, as well as storedfor later use (for example, the generated energy may be stored utilizingbatteries, heated water, hydro pumping, H₂O-to-hydrogen conversion, orthe like).

In one or more alternative embodiments, the mounting assemblies 150retain other types of electronics, such as LED drivers, DC optimizers,or other electronics that might have special PV mounting or thermalrequirements.

FIG. 2 is a top angled perspective view of a PCU mounting assembly 150coupled to a PCU 102 in accordance with one or more embodiments of thepresent invention. The PCU mounting assembly 150 comprises a base member210 generally shaped as a U-shaped rectangle and sized such that theouter edge of the base member 210 is slightly larger than the perimeterof the PCU 102. The base member 210 is formed from a non-electricallyconductive (i.e., insulating) material, such as polycarbonate (PC),p-phenylene oxide (PPO™)+polystyrene (PS), p-phenylene ether (PPE),NORYL™, LEXAN™, or the like, and is adhered to the rear face of thecorresponding PV module 104 (i.e., on the side of the PV module 104 notexposed to sunlight) as described further below with respect to FIG. 5.

The base member 210 further comprises a plurality of PCU retentionmembers 220-1, 220-2, 220-3, and 220-4, collectively referred to as PCUretention members 220. The PCU retention members 220-1, 220-2, 220-3,and 220-4 extend perpendicular from the face to the base member 210 toretain the PCU 102. Each of the PCU retention members 220 comprises atleast one PCU retention feature, such as a latch, a clip (e.g., a springclip), a trap (to hold a protuberance of the PCU 102), and the like tomechanically secure the PCU 102 to the PCU mounting assembly 150. Insome embodiments, such as the embodiment depicted in FIG. 2, the PCUretention members 220-1 and 220-2 comprise latches 222-1 and 222-2,respectively, each having a spring mechanism that retains the PCU 102until the spring is displaced (e.g., by a tool, finger, or the like) inorder to remove the PCU 102 as needed. Additionally, the PCU retentionmembers 220-3 and 220-4 each define apertures, or “traps”, suitablysized and shaped to accommodate corresponding protuberances of the PCU102. For example, as shown in detail in FIG. 2, a trap 224-A of the PCUretention member 220-4 accommodates a PCU protrusion 226-A for retainingthe PCU 102.

The PCU mounting assembly 150 further comprises one or more compressionsprings 130 that enable the PCU 102 to be maintained in one of twopositions with respect to the PV module backsheet 180 as well as changedfrom one position to the other; i.e., the position of the PCU 102 withrespect to the PV module backsheet 180 can be dynamically changed whilethe PCU 102 is mounted on the PV module backsheet 180.

As depicted in FIG. 2, the compression spring 130 is substantiallyshaped as a flat-bottom “V” (e.g., similar to a leaf spring) where theflat bottom is disposed on the top side of the arm of the base member210 that runs between the PCU retention members 220-1 and 220-4. Theobtuse-angled arms of the compression spring 130 are suitably sized andshaped such that the free ends of the arms contact the PCU 102 tomaintain the PCU 102 is one of two positions with respect to the PVmodule backsheet 180. In the first position, the PCU 102 is pressed flatto the PV module backsheet 180 such that it is not proud of the PVmodule frame, for example in shipping, if laid on the ground or racking,and the like. The PCU 102 is maintained in the first position whenpressed toward the PV module backsheet 180 or weighted down toward thePV module backsheet 180. For example, a restraining strap may be used topress the PCU 102 toward the PV module backsheet 180, or multiple PVmodule 104/PCU 102 assemblies may be stacked during shipping such thatthe compression spring 130 for each PCU mounting assembly 150 iscompressed by the next PV module 104 above in the stack (or in the caseof a vertical array the neighboring PV module 104 to the left or right).The PCU 102 moves from the first position to the second position whenforce applied to the PCU 102 toward the PV module backsheet 180 isremoved, causing the compression spring 130 to automatically spring out(for example, by releasing a restraining strap or unstacking stacked PVmodule 104/PCU 102 assemblies), resulting in the second position asdepicted in FIG. 2. The compression spring 130 maintains the PCU 102 inthe second position such that an air gap 260 exists between the PCU 102and the PV module backsheet 180 for improved thermal management of thePCU 102 and PV module backsheet 180. The air gap is generally on theorder of 10-20mm, although in other embodiments it may be larger orsmaller.

The PCU mounting assembly 150 enables the PCU 102 to be attached withvery tight lateral clearances to the PV module frame 160 and racking,whereas a sliding rail system requires almost twice the footprint wheninserting and removing the PCU 102 from the rails due to the travel downthe rails.

FIG. 3 is a top angled perspective view of a PCU mounting assembly 150in accordance with one or more embodiments of the present invention. Aspreviously described, the PCU mounting assembly 150 comprises the basemember 210, the PCU retention members 220, and the latches 222. Thetraps 224-A and 224-B are defined by the PCU retention members 220-4 and220-3, respectively.

As depicted in FIG. 3, the PCU mounting assembly 150 additionallycomprises a first compression spring 130-A and a second compressionspring 130-B (collectively referred to as compression springs 130)disposed along the parallel arms of the base member 210 such that theflat bottoms of the compression springs 130 are adhered to the surfaceof the base member 210 and the obtuse-angled arms of the compressionsprings 130 extend vertically from the base member 210 and parallel tothe base member arms. In some embodiments, the ends of the compressionspring arms may be flattened to lie flush against the PCU 102.

Generally, the compression springs 130 are formed from plastic since itdoes not need to be grounded and cannot be energized by a cut wire orcable, although in some embodiments one or both of the compressionsprings 130 may be an insulated metal spring might having a thickpolymer coating.

The compression springs 130 can be assembled by any suitable means tothe base member 210 in a secondary step. For example, the compressionsprings 130 may be adhered to the base member 210 by one or more ofglue, screws, and the like. In some other embodiments, a differentnumber of compression springs 130 may be used and/or one or more of thecompressions springs 130 may be located in a different position on thebase member 210. Additionally or alternatively, one or more of thecompression springs 130 may be shaped differently; for example, one ormore compression springs 130 may be shaped as a coil.

The base member 210 may be made with a simple two-part cavity as theundercut regions can be created by pistons from the lower mold wall.

FIG. 4 is a top angled perspective view of a PCU mounting assembly 150in accordance with another embodiment of the present invention. Aspreviously described, the PCU mounting assembly 150 comprises the basemember 210, the PCU retention members 220 and the latches 222, and thetraps 224-A and 224-B are defined by the PCU retention members 220-4 and220-3, respectively.

As depicted in FIG. 4, the outer edges of the base member arms arerecessed and the first and second compression springs 130 are disposedalong the member arms outer edges such that the obtuse-angled arms ofthe compression springs 130 extend vertically from the base member 210and parallel to the base member arms, and in a position to contact thePCU 102 when it is mounted to the PCU mounting assembly 150. In theembodiment depicted in FIG. 4, the compression springs 130 are moldedinto the base member. Although the compression springs 130 are shown inFIG. 4 along the outer edges of the base member arms, in otherembodiments one or both of the compression springs 130 may be in adifferent location on the base member 210, for example on top of thebase member arms. Additionally or alternatively, a different number ofcompression springs 130 and/or differently shaped compression springs130 may be used.

FIG. 5 is an angled bottom view of a PCU mounting assembly 150. Aspreviously described, the PCU mounting assembly 150 comprises the basemember 210, the PCU retention members 120, and the compression springs130.

A plurality of adhesive regions 502-1, 502-2, 502-3, and 502-4(collectively referred to as adhesive regions 502) are located on theunderside of the base member 210 for dispensing adhesive to adhere thebase member 210 to the PV module backsheet 180. As depicted in FIG. 5,the adhesive regions 502 are shaped as hollow oblong ovals with oneadhesive region 502 corresponding to each of the four corners of thebase member 210; e.g., in the embodiment of FIG. 5, the adhesive regions502-1, 502-2, 502-3, and 502-4 are disposed on the backsheet-facing sideof the base member 210 underneath the PCU retention members 220-1,220-2, 220-3, and 220-4, respectively. In other embodiments, differentsizes, shapes, and/or numbers of adhesive regions 502 may be used, aswell as different locations for one or more of the adhesive regions.

The base member 210 defines a tape region 504 along the underside of thebase portion between the base member arms. The tape region 504 is arecessed region defined for double-stick tape to be applied in order toadhere the base member 210 to the PV module backsheet 180 while theapplied adhesive cures. In other embodiments, a different number of taperegions 504 may be used as well as differently sized and/or located taperegions 504.

Each corner of the base member 210 defines a rectangular-shaped cut-out506-1, 506-2, 506-3, and 506-4, collectively referred to as cut-outs506. The cut-outs 506 are required to allow the latches 222 and traps224 to be formed since they are undercut regions and need a part of themold tool to penetrate the base member 210 in order to support theundercut features in the mold. Alternatively, sliding features may beadded in the mold that must be moved out of the way before the partcould be ejected from the mold.

The foregoing description of embodiments of the invention comprises anumber of elements, devices, circuits and/or assemblies that performvarious functions as described. These elements, devices, circuits,and/or assemblies are exemplary implementations of means for performingtheir respectively described functions.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

The invention claimed is:
 1. An apparatus for mechanically coupling apower conditioning unit (PCU) to a photovoltaic (PV) module, comprising:a base member comprising (i) a first side coupled to a backsheet of a PVmodule and (ii) a second side, opposite the first side such that thesecond side is positioned between the first side and the PCU, andcomprising a plurality of PCU retention members for retaining the PCU;and at least one compression spring extending from the second side ofthe base member and movable from a first position in which the PCU ispressed against the backsheet of the PV module to a second position inwhich an airgap is present between the PCU and the backsheet of the PVmodule, wherein the at least one compression spring has angled armscomprising free ends that contact the PCU to maintain the PCU in atleast one of the first position or the second position.
 2. The apparatusof claim 1, wherein the plurality of PCU retention members comprisesfour retention members including first and second retention membersdisposed opposite corresponding third and fourth retention members. 3.The apparatus of claim 1, wherein at least some of the plurality of PCUretention members comprise one of a latch, a clip, or a trap formechanically securing the PCU to the base member.
 4. The apparatus ofclaim 1, wherein the plurality of PCU retention members extendperpendicular from the second side of the base member.
 5. The apparatusof claim 1, wherein the at least one compression spring comprises afirst compression spring and a second compression spring disposed onparallel arms of the base member.
 6. The apparatus of claim 1, whereineach compression spring of the at least one compression spring issubstantially shaped as a flat-bottom “V”.
 7. The apparatus of claim 1,wherein the PCU is a DC-AC inverter.
 8. The apparatus of claim 1,wherein the PCU is a DC-DC converter.
 9. The apparatus of claim 1,wherein the at least one compression spring is one of mechanicallycoupled to the base member or molded into the base member.
 10. Theapparatus of claim 1, wherein the PCU moves from the second position tothe first position when force is applied to the PCU toward the PV modulebacksheet, and the PCU automatically moves from the first position tothe second position when the force is removed.
 11. A power moduleassembly, comprising: a photovoltaic (PV) module; a power conditioningunit (PCU); and a PCU mounting assembling comprising: a base membercomprising (i) a first side coupled to a backsheet of the PV module and(ii) a second side, opposite the first side such that the second side ispositioned between the first side and the PCU, and comprising aplurality of PCU retention members for retaining the PCU; and at leastone compression spring extending from on the second side of the basemember and movable from a first position in which the PCU is pressedagainst the backsheet of the PV module to a second position in which anairgap is present between the PCU and the backsheet of the PV module,wherein the at least one compression spring has angled arms comprisingfree ends that contact the PCU to maintain the PCU in at least one ofthe first position or the second position.
 12. The power module assemblyof claim 11, wherein the plurality of PCU retention members comprisesfour retention members including first and second retention membersdisposed opposite corresponding third and fourth retention members. 13.The power module assembly of claim 11, wherein at least some of theplurality of PCU retention members comprise one of a latch, a clip, or atrap for mechanically securing the PCU to the base member.
 14. The powermodule assembly of claim 11, wherein the plurality of PCU retentionmembers extend perpendicular from the second side of the base member.15. The power module assembly of claim 11, wherein the at least onecompression spring comprises a first compression spring and a secondcompression spring disposed on parallel arms of the base member.
 16. Thepower module assembly of claim 11, wherein each compression spring ofthe at least one compression spring is substantially shaped as aflat-bottom “V”.
 17. The power module assembly of claim 11, wherein thePCU is a DC-AC inverter.
 18. The power module assembly of claim 11,wherein the PCU is a DC-DC converter.
 19. The power module assembly ofclaim 11, wherein the at least one compression spring is one ofmechanically coupled to the base member or molded into the base member.20. The power module assembly of claim 11, wherein the PCU moves fromthe second position to the first position when force is applied to thePCU toward the PV module backsheet, and the PCU automatically moves fromthe first position to the second position when the force is removed.